Container assembly having an overcap with a storage compartment

ABSTRACT

There is provided an overcap that includes a storage compartment for receiving a product to be mixed with a hot liquid. The overcap includes a top wall defining the storage compartment in an underside of the top wall surrounded by an annular portion. The overcap includes an aperture in the annular portion. The overcap also includes a skirt extending downward from a rim surrounding the annular portion. The skirt extends below a lowermost surface of the top wall and can define a grip surface which a consumer may use to hold the container assembly, such that the grip surface insulates against heat if a hot liquid is held in the container. The storage compartment is sealed with a membrane that is relatively impermeable to moisture. In addition, the skirt includes a plurality of spacers on the inside surface of the skirt that are circumferentially spaced apart and that extend downwardly from the rim of the overcap.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention is related to overcaps for container assemblies,and more particularly, overcaps having a recessed storage compartmentfor storing of a product.

2. Description of Related Art

Convenience is a major factor in designing containers, such as cups, forholding consumable liquids, especially “travel” containers intended foreasy transport without spillage of the liquid. To this end, suchcontainers often have a lid, or overcap, affixed to the container so asto limit escape of the liquids due to changes in container orientation.Another problem with dispensing consumable liquids in containers is thatthe consumer often wishes to add various products to the liquid, such assugar or powdered cream to coffee. However, such products are typicallydistributed in small, individual packages that are not easily located oropened to dispense their contents into the liquid.

The container lid may be configured to store products that will besubsequently mixed with a liquid. U.S. Pat. No. 3,326,363 to Bennett etal. (“Bennett”) discloses a container lid with a plurality ofintegrally-formed, hollow pockets to hold products such as sugar,powdered cream, or soft-drink concentrate. A sealing member seals theproduct inside the pockets, and the sealing member may be easily torn orremoved to provide access to the product. The Bennett patent, andsimilar lids with hollow pockets, do not provide an aperture forconvenient access to the liquid or product within the container, thusrequiring the consumer to remove the lid to gain access to the liquid.

Containers for consumable liquids, particularly hot liquids, ofteninclude a sleeve to insulate against the heat from the hot liquid in thecontainer. U.S. Pat. No. 5,765,716 to Cai et al. discloses a lidintegrally formed with a sleeve that insulates the wall of thecontainer. The sleeve is tethered to the lid and is configured toslidably receive the container. Connection of the lid to the containermay be difficult for consumers because the container must first beinserted into the sleeve and then the tethered lid must be rotated toattach the lid to the open upper end.

A need exists for a container lid or overcap that provides convenientaccess to liquids and includes a storage compartment for a product to bemixed with the liquid. A need also exists for a lid that is easilyattached to a container and that provides a grip surface that insulatesagainst heat from a hot liquid.

BRIEF SUMMARY OF THE INVENTION

The invention addresses the above needs and achieves other advantages byproviding an overcap for a container, wherein the overcap can store aproduct for mixing with a liquid held in the container. The overcapincludes a rim configured to engage the container and a top wall thatdefines a storage compartment in an underside of the top wall. The topwall also includes a substantially horizontal annular portion radiallyinward of the rim and surrounding the storage compartment. The overcapalso has a membrane removably attached to the underside of the top wallof the overcap covering the storage compartment for sealing a product inthe storage compartment. The overcap may also be made of a multi-layerpolymer material to provide oxygen and moisture protection. A drinkingaperture is defined in the annular portion to provide convenient accessto liquids that may be held in the container.

The overcap of further embodiments includes a skirt extending downwardlyfrom the rim and includes a grip surface defined on the skirt. The skirtmay include a plurality of spacers along an inner surface of the skirt,and the spacers may be circumferentially spaced apart from each otherand extend downwardly from the rim of the overcap. The grip surface canbe held by the consumer to support the container assembly when a hotliquid is held in the container. In addition, the spacers of the skirtinsulate against heat from the hot liquid by spacing the skirt from thecontainer wall.

Likewise, another embodiment of the present invention provides anovercap for a container, wherein the overcap includes a rim configuredto engage the container and a top wall that defines a storagecompartment in an underside of the top wall. The top wall also includesa substantially horizontal annular portion radially inward of the rimand surrounding the storage compartment. The overcap also has a membraneremovably attached to the underside of the top wall of the overcapcovering the storage compartment for sealing a product contained in thestorage compartment. A skirt extends downwardly from the rim andincludes a grip surface defined on the skirt. The grip surface can beheld by the consumer to support the container assembly when a hot liquidis held in the container and may insulate against heat from the hotliquid.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Having thus described the invention in general terms, reference will nowbe made to the accompanying drawings, which are not necessarily drawn toscale, and wherein:

FIG. 1 is a perspective view of a container assembly in accordance withone embodiment of the present invention, illustrating the membrane ofthe overcap being removed to expose the product within the storagecompartment;

FIG. 2 is a schematic, cross-sectional view of the container assembly ofFIG. 1, showing the product stored within the storage compartment;

FIG. 3 is a perspective view of a container assembly in accordance witha second embodiment of the present invention, illustrating the membraneof the overcap being removed to expose the product within the storagecompartment; and

FIG. 4 is a schematic, cross-sectional view of the container assembly ofFIG. 3, showing the product stored within the storage compartment.

DETAILED DESCRIPTION OF THE INVENTION

The present invention now will be described more fully hereinafter withreference to the accompanying drawings, in which some, but not allembodiments of the invention are shown. Indeed, the invention may beembodied in many different forms and should not be construed as limitedto the embodiments set forth herein; rather, these embodiments areprovided so that this disclosure will satisfy applicable legalrequirements. Like numbers refer to like elements throughout.

With reference to FIGS. 1 and 2, a container assembly 10 in accordancewith one embodiment of the invention is illustrated. The containerassembly 10 of FIG. 1 includes a lid or overcap 12 and a container 14that defines a cup. Further embodiments of the present invention maycomprise alternative containers. The container 14 is structured to holda liquid, in particular a hot liquid, which can be inserted into thecontainer and removed from the container, through a top opening 16. Thecontainer 14 of FIG. 1 is a tapered cup of a paper, plastic, or expandedpolystyrene material, to list three non-limiting examples. The container14 includes a bottom wall 18 and a generally tubular side wall 20 thatis integrally formed with and upstanding from the bottom wall andterminates at a top edge 22. As shown, the side wall 20 may taper suchthat the diameter is larger at the opening 16 than at the bottom wall18. The top edge 22 encircles and defines the opening 16 of thecontainer 14. The top edge 22 can also include a bead that projectsradially outward from the top edge of the side wall 20 to provide animproved surface for securing the overcap 12 to the container 14. Theillustrated overcap 12 and container 14 are generally circular, but thepresent invention may also include container assemblies 10 of anygeometric shape or relative size. In addition, the container 14 may be acontainer for holding non-liquid products.

The overcap 12 has a top wall 24 that is configured to extend over theopening 16 of the container 14 when the overcap is secured thereon. Thetop wall 24 defines a recessed storage compartment 26 in an underside ofthe top wall. The storage compartment 26 is configured to receive aproduct 28 that is kept in the storage compartment by a removablyattached membrane 30. The membrane 30 is removable, as indicated by thearrow in FIG. 1, to provide access to the product 28, preferably whenthe product is to be mixed with a hot liquid in the container 14. Themembrane 30 can be completely removed from the overcap 12 by theconsumer when the consumer removes the product 28; however, the membranecan also remain attached to the overcap after removal of the product 28.The membrane 30 is initially attached to the underside of the top wall24 during the manufacture of the container assembly 10 after the product28 has been placed in the storage compartment 26.

The membrane 30 of the illustrated embodiment is constructed of amembranous material that is relatively impermeable to moisture. Examplesof such membranous material include, but are not limited to metal foil,polyethylene terephthalate, metallized polyethylene terephthalate,polyethylene naphthalate, metallized polypropylene, metal oxide andsilicate coated polyester, metal oxide and silicate coatedpolypropylene, ethylene vinyl alcohol copolymer, and mixtures thereof.The membrane 30 preferably prevents the ingress of moisture and theegress of the product 28 while the membrane is fully attached to theunderside of the top wall 24.

The top wall 24 further includes an annular portion 32 surrounding thestorage compartment 26. The annular portion 32 of FIG. 1 is asubstantially horizontal surface that defines a drinking aperture 34.The aperture 34 provides access to a liquid in the container 14, whichmay be a hot liquid into which the stored product 28 is mixed, such thata consumer can drink the liquid without removing the overcap 12. Theaperture 34 of FIG. 1 includes two parallel walls joined by two arcuatewalls; however, apertures of further embodiments of the invention mayhave any geometric pattern or may be of any size relative to the annularportion 32.

Surrounding the annular portion 32 is a rim 36, as illustrated in FIG.2. The rim 36 defines a recess 38 that is sized to engage the top edge22 of the side wall 20 of the container 14. The engagement of the recess38 and the top edge 22 holds the top wall 24 of the overcap 12 inposition over the opening 16. The recess 38 defines a channel within therim 36 that preferably provides an interference fit with the top edge22, by virtue of the width of the recess being less than the thicknessof the top edge when the overcap 12 is in an undeformed free state. Therecess 38 preferably engages the top edge 22 along the entirecircumference of the top edge to also provide a sealed interface toprevent the product, which is typically a liquid, from passing betweenthe overcap 12 and the top edge 22.

Extending downwardly from the rim 36 is the skirt 40, as shown in FIG.2. The skirt 40 is attached to the rim 36 and encircles a top portion 42of the container 14. The top portion 42 of the container 14 is theportion of the side wall 20 opposite the bottom wall 18 and includes thetop edge 22. In other words, the top portion 42 is the side wall 20immediately below the top edge 22. The skirt 40 may extend perpendicularto the substantially horizontal annular portion, or the skirt may extendgenerally parallel to the top portion 42 of the container. In addition,the skirt 40 can flare outwardly, as in FIG. 2. The skirt 40 preferablyextends downwardly below a lowermost surface of the top wall 24. Asillustrated in FIG. 2, the lowermost surface of the top wall 24 is thesurface to which the membrane 30 is attached.

The skirt 40 defines a grip surface 44, which a consumer may grasp tohold the container assembly 10 and which may insulate the consumeragainst heat if a hot liquid is held in the container 14. The gripsurface 44 may be of any axial length that is sufficient to allow acustomer to hold the container assembly 10 with or without touching theremainder of the overcap 12 or container 14. The overcap 12 of FIG. 1has a grip surface 44 of at least approximately 0.5 inch in length,though the grip surface is preferably at least 1 inch in length andstill more preferably is 2 inches in length, as illustrated in FIGS. 3and 4.

A second embodiment of the container assembly 110 is illustrated inFIGS. 3 and 4, wherein the overcap 112 includes a skirt 140 thatprovides a grip surface 144. The grip surface 144 extends downwardlyfrom the rim 136 of the overcap 112 and is intended to be a surface aconsumer can grasp to hold the container assembly 110 when the liquid inthe container is hot. The container 114 includes a bottom wall 118 and aside wall 120 upstanding from the bottom wall and terminating at a topedge 122. The top edge 122 encircles and defines a top opening 116 ofthe container 114, and the top edge can also include a bead thatprojects radially outward from the top edge.

The overcap 112 of FIGS. 3 and 4 has a top wall 124 configured to extendover the opening 116 of the container 114 when the overcap is securedthereon. The top wall 124 defines a recessed storage compartment 126 onan underside of the top wall. The storage compartment 126 is configuredto receive a product 128 that is sealed in the storage compartment by amembrane 130. The membrane 130 is removable, as indicated by the arrowin FIG. 3, to provide access to the product 128. The membrane 130 isremovably attached to a surface on the underside of the top wall 124during the manufacture of the container assembly 110. The membrane 130is also relatively impermeable to moisture.

The top wall 124 further includes an annular portion 132 surrounding thestorage compartment 126. The annular portion 132 of FIG. 3 is asubstantially horizontal surface that defines a drinking aperture 134.The aperture 134 provides access to a liquid in the container 114 andcan have any geometric pattern or be of any size relative to the annularportion 132. Surrounding the annular portion 132 is a rim 136, asillustrated in FIG. 4. The rim 136 defines a recess 138 that is sized toengage the top edge 122 of the side wall 120 of the container 114 tohold the overcap 112 in position over the opening 116. The recess 138preferably provides an interference fit with the top edge 122 andpreferably engages the top edge along the entire circumference of thetop edge to provide a sealed interface.

Extending downwardly from the rim 136 is the skirt 140, as shown in FIG.4. The skirt 140 is attached to the rim 136 and encircles a top portion142 of the container 114. The top portion 142 of the container 114 isimmediately below the top edge 122. The skirt 140 includes a gripsurface 144, which a consumer may grasp to hold the container assembly110. The grip surface 144 is preferably 2 inches in axial length in theembodiment illustrated in FIG. 4. The skirt 140 also extends downwardlybelow a lowermost surface of the top wall 124, which is the surface towhich the membrane 130 is attached, similar to the embodiment of FIG. 2.

The skirt 140 of FIG. 3 also includes a plurality of spacers 146 on aninner surface 148 of the skirt. The spacers 146 are circumferentiallyspaced apart from each other and extend downwardly from the rim 136 ofthe overcap 112 to an end of the skirt 140 opposite the rim. The spacers146 can improve the engagement between the overcap 112 and the container114 if the spacers are sized to create an interference fit with the sidewall 120 of the container, as illustrated in FIG. 4. The spacers 146project radially inwardly from the inner surface 148 of the skirt 140and radially space the skirt from the container side wall 120 toinsulate against the heat of a hot liquid in the container 114 byproviding a continuous pocket, or individual pockets, of air between theside wall 120 and the skirt 140 that reduce the thermal transfer to theskirt. Therefore, the skirt 140 of FIGS. 3 and 4 provides a grip surface144 that a consumer can grasp to hold the container assembly 110 and toinsulate the consumer's hand when the liquid in the container 114 ishot.

The storage compartment 26 and 126 of FIGS. 2 and 4, respectively, is afrustoconical chamber that includes a flat top surface. This domedportion of the top wall 24 and 124 defines the storage compartment 26and 126, respectively. Further embodiments of the present inventioninclude storage compartments of any shape, a non-limiting example beinghemispherical. In addition, the storage compartment 26 and 126 ofadditional embodiments also include a desiccant to absorb moisture sothat the product, which is preferably a powder, is exposed to a minimalamount of moisture. The desiccant can be joined to the inside surface ofthe storage compartment 26 and 126 or can be incorporated as a layer ofthe membrane 30 and 130. Non-limiting examples of desiccant materialinclude sodium phosphate di-basic, calcium oxide, sucrose, gelatin,bentonite clay, and silica gel.

The annular portion 32 and 132 of FIGS. 2 and 4, respectively, define astacking surface upon which another container 14 and 114 can be stackedso that the top container is firmly supported by the overcap 12 or 112of the bottom container. The bottom wall 18 and 118 of the container 14and 114, respectively, defines a recess structured and arranged toreceive the top wall 24 and 124 of the compartment 26 and 126 of theovercap 12 and 112. Advantageously, the recess of the bottom wall 18 and118 prevents lateral sliding of the stacked container relative to thebottom container. Further embodiments of the overcap 12 and 112 maydefine an edge of the rim 36 and 136 that engages the bottom of the sidewall 20 or 120 to prevent lateral sliding of the stacked containerrelative to the bottom container. Still further embodiments of thepresent invention may comprise alternative stacking surfaces or featuresfor secure stacking of a top container onto the overcap of a bottomcontainer.

To manufacture the container assembly 10 of the present invention, thecontainer 14 and the overcap 12 are individually formed. Preferably, theovercap 12 is thermoformed, injected molded, or blow molded from apolymer material. The overcap 12 may be formed to include a multi-layerpolymer structure to provide oxygen and moisture barrier should thepackaged product require such a barrier. After the overcap 12 hardens,the product 28 can be inserted into the storage compartment 26 and themembrane 30 attached to the underside of the top wall 24. The membrane30 is attached to the overcap 12 by any suitable process, which includeconductive heat sealing, ultrasonic sealing, the applying of adhesives,or any other joining method. Once the product 28 is securely stored inthe storage compartment 26, the overcap 12 can be paired with thecontainer 14 to complete the container assembly 10.

Many modifications and other embodiments of the invention set forthherein will come to mind to one skilled in the art to which theinvention pertains having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the invention is not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the appended claims.Although specific terms are employed herein, they are used in a genericand descriptive sense only and not for purposes of limitation.

1. An overcap for a container, wherein the overcap can store a product for mixing with a liquid held in the container, the overcap comprising: a rim configured to engage the container; a top wall defining a storage compartment in an underside of the top wall, the top wall having a substantially horizontal annular portion radially inward of the rim and surrounding the storage compartment, a drinking aperture being defined in the annular portion; and a membrane removably attached to the underside of the top wall of the overcap covering the storage compartment for sealing a product contained in the storage compartment.
 2. An overcap of claim 1, further comprising a skirt extending downwardly from the rim.
 3. An overcap of claim 2, wherein the skirt defines a grip surface.
 4. An overcap of claim 3, wherein the skirt extends below a lowermost surface of the top wall of the overcap.
 5. An overcap of claim 3, wherein the skirt includes a plurality of spacers extending along an inner surface of the skirt.
 6. An overcap of claim 5, wherein the plurality of spacers are circumferentially spaced apart from each other and extend downwardly from the rim of the overcap.
 7. An overcap of claim 1, wherein the storage compartment defines a domed portion.
 8. An overcap of claim 7, wherein the domed portion has incorporated therein a desiccant.
 9. An overcap of claim 1, wherein the membrane is relatively impermeable to moisture.
 10. An overcap for a container, wherein the overcap can store a product for mixing with a liquid held in the container, the overcap comprising: a rim configured to engage the container; a top wall defining a storage compartment in an underside of the top wall, the top wall having a substantially horizontal annular portion radially inward of the rim and surrounding the storage compartment; a skirt extending downwardly from the rim, wherein the skirt defines a grip surface; and a membrane removably attached to the underside of the top wall of the overcap covering the storage compartment for sealing a product contained in the storage compartment.
 11. An overcap of claim 10, wherein the skirt extends below a lowermost surface of the top wall of the overcap.
 12. An overcap of claim 11, wherein the skirt includes a plurality of spacers extending along an inner surface of the skirt.
 13. An overcap of claim 12, wherein the plurality of spacers are circumferentially spaced apart from each other and extend downwardly from the rim of the overcap.
 14. An overcap of claim 13, wherein the storage compartment defines a domed portion.
 15. An overcap of claim 14, wherein the domed portion has incorporated therein a desiccant.
 16. An overcap of claim 10, wherein the membrane is relatively impermeable to moisture.
 17. An overcap of claim 10, further comprising a drinking aperture defined in the annular portion.
 18. A container assembly comprising: a container comprising a bottom wall and a tubular side wall upstanding from the bottom wall, the side wall having a top edge encircling a top opening of the container; a cap having rim configured to engage the top edge of the container, the cap having a top wall defining a storage compartment in an underside of the top wall, the top wall having a substantially horizontal annular portion radially inward of the rim and surrounding the storage compartment, a drinking aperture being defined in the annular portion; and a membrane removably attached to the underside of the top wall of the overcap covering the storage compartment for sealing a product contained in the storage compartment.
 19. A container assembly of claim 18, further comprising a skirt extending downwardly from the rim.
 20. A container assembly of claim 19, wherein the skirt extends below a lowermost surface of the top wall of the overcap and defines a grip surface.
 21. A container assembly of claim 20, wherein the skirt includes a plurality of spacers extending along an inner surface of the skirt, wherein the plurality of spacers are circumferentially spaced apart from each other and extend downwardly from the rim of the overcap.
 22. A container assembly of claim 18, wherein the membrane is relatively impermeable to moisture. 